Gas red condensing wall hung
combination boilers
G.C.N : 47-116 - 62 (24 kW)
G.C.N : 47-116 - 63 (30 kW)
G.C.N : 47-116 - 64 (38 kW)
E-COMBI 24
E-COMBI 30
E-COMBI 38
Country of destination GB, IE
2
overview
INDEX
Overview
General Information ........................................................... 3
Advice for the Installer ....................................................... 4
CE Labelling ........................................................................... 4
Data Plate Symbols ............................................................. 4
Safety Regulations ..............................................................5
Product description
Control Panel.........................................................................6
Overall View ........................................................................... 7
Overall Dimension .............................................................. 8
Minimum Clearances .........................................................8
Technical Information ........................................................ 9
Installation
Reference Standards ........................................................10
Condensate Discharge ....................................................13
Installing the Boiler ........................................................... 14
Gas Connection ..................................................................15
Water Connection .............................................................15
Instructions for Opening the Casing and Performing
an Internal Inspection ...................................................... 15
Connecting the Flue .........................................................17
Fitting the Coaxial Flue (Ø 60/100 Horizontal) ........18
Fitting the 5” Flue (Ø 80/125 Horizontal / Vertical) 19
Fitting the Coaxial Flue (Ø 60/100 Vertical) .............. 20
Fitting the Twin Pipe (Ø 80/80) .....................................21
Electrical Connections .....................................................25
Peripheral Unit Connection ...........................................25
Room Thermostat Connection .....................................26
Outdoor Sensor Connection .........................................26
Electrical Diagram .............................................................27
Commissioning
Initial Preparation .............................................................. 28
Electricity Supply ...............................................................28
Filling the Heating System .............................................28
Filling of the DHW System ..............................................28
Gas Supply ...........................................................................28
Water Treatment ................................................................28
First Igniton Operation .................................................... 29
Ignition procedure ............................................................ 30
Test Function and Combustion Analysis ...................32
Boiler Protection Devices
Boiler Protection Devices ...............................................33
Anti-Frost Device ...............................................................33
Table summarising error codes ....................................33
Maintenance
General Comments ...........................................................34
General Access ...................................................................36
Electrical Unit ......................................................................37
Hydraulic Unit ..................................................................... 39
Burner Unit ..........................................................................47
Fan Unit .................................................................................50
Gas Valve ...............................................................................51
Annual Maintenance ........................................................ 52
Benchmark Commissioning Checklist .......................53
Benchmark Service Interval Record ............................54
Spare Parts Short List .......................................................55
3
overview
These instructions are suitable for E-COMBI boilers :
Do not forget the Log Book!
MTS supports Benchmark, the heating industry code to ensure the correct installation,
commissioning and servicing of domestic central heating systems.
To The Householder
Make sure you have a completed Log Book for your boiler. This provides a record of the
commissioning of your boiler.
It contains important information about your particular installation that may be required by service
engineers. The Log Book will also provide contact details for the installer should you need guidance
in the use of this appliance or if there are any problems.
As with your car, your boiler will work more reliably and eciently if regularly serviced. We recommend
an annual service check. The service history of the appliance will be recorded on the Log Book.
In the unlikely event of any problems with your boiler or system you should rst contact your
installer. If your installer cannot resolve the problem he should telephone our national service
helpline.
A charge may be made if MTS Service is called out to resolve a non-product related fault.
Your statutory rights are not aected.
To The Installer
As part of the commissioning of this appliance it is vital that the Log Book is completed and given to the
Householder. Please ensure that your customer is aware of the importance of keeping the Log Book safe as a
record of the installation and the appliance service history.
Please ensure that your customer is aware of the correct operation of the system, boiler and controls.
MTS recommend the use of protective clothing, when installing and working on the appliance i.e. gloves.
CUSTOMER CARE
MTS, as a leading manufacturer of domestic and commercial water heating appliances is committed to
providing high quality products and a high quality after sales service.
Advice on installation or servicing can also be obtained by contacting the MTS Technical and Customer
Service Departments at High Wycombe.
TECHNICAL DEPARTMENT CUSTOMER SERVICE
DEPARTMENT
Tel: 0870 241 8180 Tel: 0870 600 9888
Fax: 01494 459775 Fax: 01494 459775
GUARANTEE
The manufacturer’s guarantee is for 2 years from the date of purchase. The guarantee is invalidated if
the appliance is not installed in accordance with the recommendations made herein or in a manner not
approved by the manufacturer. To assist us in providing you with an ecient after sales service, please
return the guarantee registration card enclosed with the boiler without delay.
CAUTION
In the United Kingdom, installation, start-up, adjustments and maintenance, must be performed by a
competent person only, in accordance with the current Gas Safety (Installation & Use) Regulations and the
instructions provided.
In the Republic of Ireland, the installation and initial start up of the appliance must be carried out by a
Competent Person in accordance with the current edition of I.S.813 “Domestic Gas Installations”, the current
Buidling Regulations, reference should also be made to the current ETCI rules for electrical installation.
All CORGI registered installers carry a CORGI ID card, and have a registration number. Both should be
recorded in your boiler Log Book. You can check your installer is CORGI registered by calling CORGI
direct on:- (01256) 372300.
Improper installation may cause damage or injury to individuals, animals and personal property for which
the manufacturer will not be held liable. To ensure ecient and safe operation it is recommended that the
boiler is serviced annually by a competent person.
If it is known that a fault exists on the appliance, it must not be used until the fault has been corrected by a
competent person.
This instruction booklet is especially designed for appliances installed in the UK and the Republic of Ireland
4
overview
Advice for the installer
The installation and rst ignition of the
boiler must be performed by qualied personnel
in compliance with current national regulations
regarding installation, and in conformity with
any requirements established by local authorities
and public health organisations.
After the boiler has been installed, the installer
must ensure that the end user receives the
declaration of conformity and the operating
manual, and should provide all necessary
information as to how the boiler and the safety
devices should be handled.
This appliance is designed to produce hot water for
domestic use.
It should be connected to a heating system and a
distribution network for domestic hot water, both of
which must be compatible with its performance and
power levels.
The use of the appliance for purposes other than
those specied is strictly forbidden. The manufacturer
cannot be held responsible for any damage caused
by improper, incorrect and unreasonable use of
the appliance or by the failure to comply with the
instructions given in this manual.
Installation, maintenance and all other interventions
must be carried out in full conformity with the
governing legal regulations and the instructions
provided by the manufacturer. Incorrect installation
can harm persons, animals and possessions;
the manufacturing company shall not be held
responsible for any damage caused as a result.
The boiler is delivered in a carton. Once you have
removed all the packaging, make sure the appliance
is intact and that no parts are missing. If this is not
the case, please contact your supplier.
Keep all packaging material (clips, plastic bags,
polystyrene foam, etc.) out of reach of children as it may
present a potential hazard.
In the event of a fault and/or malfunction, turn
the appliance o, turn o the gas cock and do not
attempt to repair it yourself. Contact a qualied
professional instead.
Before any maintenance or repair work is performed
on the boiler, make sure you have disconnected it
from the electricity supply by switching the external
bipolar switch to the “OFF” position and removing
the fuse.
All repairs, which should only be performed using
original spare parts, should be carried out by a
qualied professional. Failure to comply with the
above instructions could compromise the safety of
the appliance and invalidate all liability on the part
of the manufacturer.
In the event of any maintenance or other structural
work in the immediate vicinity of the ducts or ue
gas exhaust devices and their accessories, switch
the appliance o by switching the external bipolar
switch to the “OFF” position and shutting o the gas
control valve. When the work has been completed,
ask a qualied technician to check the eciency of
the ducting and the devices.
Turn the boiler o and turn the external switch “OFF”
to clean the exterior parts of the appliance.
Clean using a cloth dampened with soapy water. Do
not use aggressive detergents, insecticides or toxic
products. If the appliance is used in full compliance
with current legislation, it will operate in a safe,
environmentally-friendly and cost-ecient manner.
If using kits or optional extras, make sure they are
authentic.
CE labelling
The CE mark guarantees that the appliance conforms
to the following directives:
-
90/396/CEE
relating to gas appliances
-
2004/108/CEE
relating to electromagnetic compatibility
-
92/42/CEE
relating to energy eciency
-
2006/95/CEE
relating to electrical safety
Symbols used on the data plate
Gas
MAX
MIN
Gas
mbar
mbar
1
2
5
4
3
6
7
19
8
9
10
11
12
14
15
16
17
18
13
20
21
22
Légende :
1.
Brand
2. Manufacturer
3. Boiler model - Serial number
4. Commercial reference
5. certication number
6. Destination country - gas category
7. Gas setting
8. Installation
type
9. Electrical data
10. Maximum domestic hot water pressure
11. Maximum heating pressure
12. Boiler type
13. NOx class / Eciency
14. Input rating nominal heating
15. Power ouput
heating
16. DHW specic ow rate
17. Boiler output eciency
18. Input rating nominal DHW
19. Gases which may be used
20. Température ambiante de fonctionnement
21. Max. central heating temperature
22. Max. Domestic Hot Water temperature
5
overview
Safety regulations
Key to symbols:
Failure to comply with this warning implies the risk of
personal injury, in some circumstances even fatal
Failure to comply with this warning implies the risk
of damage, in some circumstances even serious, to
property, plants or animals.
Install the appliance on a solid wall which is not
subject to vibration.
Noisiness during operation.
When drilling holes in the wall for installation
purposes, take care not to damage any electrical
wiring or existing piping.
Electrocution caused by contact with live wires.
Explosions, res or intoxication caused by gas
leaking from damaged piping. Damage to existing
installations. Flooding caused by water leaking from
damaged piping.
Perform all electrical connections using wires
which have a suitable section.
Fire caused by overheating due to electrical current
passing through undersized cables.
Protect all connection pipes and wires in order to
prevent them from being damaged.
Electrocution caused by contact with live wires.
Explosions, res or intoxication caused by gas leaking
from damaged piping. Flooding caused by water
leaking from damaged piping.
Make sure the installation site and any systems to
which the appliance must be connected comply
with the applicable norms in force.
Electrocution caused by contact with live wires
which have been installed incorrectly. Damage to the
appliance caused by improper operating conditions.
Use suitable manual tools and equipment (make
sure in particular that the tool is not worn out
and that its handle is xed properly); use them
correctly and make sure they do not fall from
a height. Replace them once you have nished
using them.
Personal injury from the falling splinters or fragments,
inhalation of dust, shocks, cuts, pricks and abrasions.
Damage to the appliance or surrounding objects
caused by falling splinters, knocks and incisions.
Use electrical equipment suitable for its intended
use (in particular, make sure that the power
supply cable and plug are intact and that the parts
featuring rotary or reciprocating motions are
fastened correctly); use this equipment correctly;
do not obstruct passageways with the power
supply cable, make sure no equipment could fall
from a height. Disconnect it and replace it safely
after use.
Personal injury caused by falling splinters or
fragments, inhalation of dust, knocks, cuts, puncture
wounds, abrasions, noise and vibration. Damage
to the appliance or surrounding objects caused by
falling splinters, knocks and incisions.
Make sure any portable ladders are positioned
securely, that they are suitably strong and that
the steps are intact and not slippery and do not
wobble when someone climbs them. Ensure
someone provides supervision at all times.
Personal injury caused by falling from a height or cuts
(stepladders shutting accidentally).
Make sure any rolling ladders are positioned
securely, that they are suitably strong, that the
steps are intact and not slippery and that the
ladders are tted with handrails on either side of
the ladder and parapets on the landing.
Personal injury caused by falling from a height.
During all work carried out at a certain height
(generally with a dierence in height of more
than two metres), make sure that parapets are
used to surround the work area or that individual
harnesses are used to prevent falls. The space
where any accidental fall may occur should be
free from dangerous obstacles, and any impact
upon falling should be cushioned by semi-rigid or
deformable surfaces.
Personal injury caused by falling from a height.
Make sure the workplace has suitable hygiene and
sanitary conditions in terms of lighting, ventilation
and solidity of the structures.
Personal injury caused by knocks, stumbling etc.
Protect the appliance and all areas in the vicinity
of the work place using suitable material.
Damage to the appliance or surrounding objects
caused by falling splinters, knocks and incisions.
Handle the appliance with suitable protection and
with care.
Damage to the appliance or surrounding objects
from shocks, knocks, incisions and squashing.
During all work procedures, wear individual
protective clothing and equipment.
Personal injury caused by electrocution, falling
splinters or fragments, inhalation of dust, shocks, cuts,
puncture wounds, abrasions, noise and vibration.
Place all debris and equipment in such a way
as to make movement easy and safe, avoiding
the formation of any piles which could yield or
collapse.
Damage to the appliance or surrounding objects
from shocks, knocks, incisions and squashing.
All operations inside the appliance must be
performed with the necessary caution in order to
avoid abrupt contact with sharp parts.
Personal injury caused by cuts, puncture wounds and
abrasions.
Reset all the safety and control functions aected
by any work performed on the appliance and make
sure they operate correctly before restarting the
appliance.
Explosions, res or intoxication caused by gas leaks or
an incorrect ue gas exhaust. Damage or shutdown
of the appliance caused by out-of-control operation.
Before handling, empty all components that may
contain hot water, carrying out any bleeding if
necessary.
Personal injury caused by burns.
Descale the components, in accordance with
the instructions provided on the safety data
sheet of the product used, airing the room,
wearing protective clothing, avoid mixing
dierent products, and protect the appliance and
surrounding objects.
Personal injury caused by acidic substances coming
into contact with skin or eyes; inhaling or swallowing
harmful chemical agents. Damage to the appliance
or surrounding objects due to corrosion caused by
acidic substances.
If you detect a smell of burning or smoke, keep
clear of the appliance, disconnect it from the
electricity supply, open all windows and contact
the technician.
Personal injury caused by burns, smoke inhalation,
intoxication.
6
product description
90°40°
50°
60° 70°
80°
on/o
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
9
6
12
I
1
2
3
4
5
8
9
10
6
7
Control panel
Legend :
1. Green indicator CH temperarure and errors indicator
2. ON/OFF button
3. Green indicator ON/OFF
4.
Pressure gauge
5. Winter / Summer switch - Heating temperature regulation knob
6. Domestic Hot Water adjustment knob
7. Time clock
8. Green indicator : ame ON
Red indicator : locking light
9. Yellow
indicator : fumes exhaust malfunction
10. R
ESET button
7
product description
1. ue connector
2.
air pressure switch
3. burner
4.
detection Electrode
6.
C.H. Return temperature probe
7.
C.H. Flow temperature probe
8.
gas valve
9.
secondary heat exchanger
11. siphon
12. C.H. pressure relief valve
13. electrical box
15.
C.H. circuit lter
16.
D.H.W. Flow switch
17.
circulation Pump with air release valve
18.
diverter valve
19.
switch On-O
20. silencer
21.
modulating Fan
22.
ignition electrodes
23. ignitor
24. thermal fuse
25.
combustion Analysis Test Point
Overall view
1
2
3
4
6
7
8
9
11
12
13
25
24
23
22
21
20
18
19
17
15
16
8
product description
28
770
200
150
120 120
200
180
65 6567 67
25770
Overall Dimensions
24/30/38
A. Central Heating Flow
B. Domestic Hot Water Outlet
C. Gas Inlet
D. Domestic Cold Water Inlet
E. Central Heating Return
450
003
003
50 50
Minimum clearances
In order to allow easy
access to the boiler for
maintenance operations,
The boiler must be installed
in accordance with the
clearances stated below.
5
5
9
product description
Technical Data
GENERAL
NOTE
Model E-COMBI
243038
CE Certication (pin)
0085BR0347
Boiler type
B23-C13-C33-C43-C53-C83
POWER SPECIFICATIONS
Max/min nominal caloric ow rate (Pci) Qn
KW
22,0/5,5
28,0/6,5
31,0/7,5
Max/min nominal caloric ow rate (Pcs) Qn
KW
24,4/6,1
31,1/7,2
34,4/8,3
Domestic hot water max/min nominal caloric ow rate (Pci) Qn
KW
25,0/5,5
30,0/6,5
38,0/7,5
Domestic hot water max/min nominal caloric ow rate (Pcs) Qn
KW
27,8/6,1
33,3/7,2
42,2/8,3
Max/min power output (80°C-60°C) Pn
KW
21,6/5,2
27,4/6,2
30,3/7,3
Max/min power output (50°C-30°C) Pn
KW
23,5/5,8
29,5/6,9
33,1/8,0
Domestic hot water max/min power output Pn
KW
25,0/5,0
30,0/6,0
38,9/7,1
Combustion eciency (of ue gas)
%
97,9
97,9
98,0
Nominal caloric ow rate eciency (60/80°C) Hi/Hs
%
98,0/88,2
98,0/88,2
97,6/87,9
Nominal caloric ow rate eciency (30/50°C) (condensation) Hi/Hs
%
107,0/96,4
105,3/94,8
106,9/96,3
Eciency at 30% at 30°C (condensation) Hi/Hs
%
108,0/97,3
110,3/99,3
107,2/96,5
Eciency at 30% at 47°C Hi/Hs
%
101,0/90,9
98,2/88,4
103,1/92,8
Minimum caloric ow rate eciency (60/80°C) Hi/Hs
%
95,0/85,5
95,6/86,1
96,8/87,2
Eciency rating (dir. 92/42/EEC)
stars
****
****
****
Sedbuk class
class
A / 90,3
A / 90,1
A / 90,1
Loss when stopped (∆T = 50°C)
%
0,2
0,1
0,1
Loss of burner gas when operating
%
2,1
2,1
2,0
EMISSIONS
Available air pressure
Pa
137
141
132
NoX class
class555Flue gas temperature (G20) (80°C-60°C)
°C636363CO2 content (G20) (80°C-60°C)
%
9,0
9,0
9,6
CO content (0%O2) (80°C-60°C)
ppm
< 100
< 100
< 125
O2 content (G20) (80°C-60°C)
%
4,5
4,5
3,5
Maximum ue gas ow (G20) (80°C-60°C)
Kg/h
41,2
49,4
59,2
Excess air (80°C-60°C)
%2727
20
HEATING CIRCUIT
Expansion chamber ination pressure
bar11
1
Maximum heating pressure
bar33
3
Expansion chamber capacity
L
6,5
6,5
6,5
Maximum water capacity with in the appliance (75°C-35°C)
L
100/300
100/300
100/300
Min/max heating temperature (high temperature range)
°C
35/82
35/82
35/82
Min/max heating temperature (low temperature range)
°C
20/45
20/45
20/45
DOMESTIC HOT WATER
CIRCUIT
Domestic hot water max/min temperature
°C
36/60
36/60
36/60
Specic ow rate of domestic hot water (∆T=30°C)
l/mn
12,0
15,0
18,2
Quantity of hot water ∆T=25°C
l/mn
14,4
18,0
21,8
Quantity of hot water ∆T=35°C
l/mn
10,3
12,9
15,6
Hot water comfort rating (EN13203)
stars
***
***
***
Hot water minimum ow rate
l/mn
< 2
< 2
< 2
Domestic hot water max/min pressure
bar
7/0,3
7/0,3
7/0,3
ELECTRICAL
Power supply frequency/voltage
V/Hz
230/50
230/50
230/50
Total electrical power absorbed
W
114
115
150
Minimum ambient temperature for use
°C+5+5
+5
Protection level for the electrical appliance
PI
X5D
X5D
X5D
Weightkg323535,5
10
installation
Reference Standards
In the United Kingdom, the installation and initial
start-up of the boiler must be by a CORGI registered
installer in accordance with the installation standards
currently in eect, as well as with any and all local
health and safety standards i.e. CORGI.
In the Republic of Ireland the installation and initial
start-up of the appliance must be carried out by a
Competent Person in accordance with the current
edition of I.S.813 “Domestic Gas Installations” and
the current Building Regulations, reference should
also be made to the current ETCI rules for electrical
installation.
The installation of this appliance must be in
accordance with the relevant requirements of the
Local Building Regulations, the current I.E.E. Wiring
Regulations, the by-laws of the local authority, in
Scotland, in accordance with the Building Standards
(Scotland) Regulation and Health and Safety
document No. 635, “Electricity at Work Regulations
1989” and in the Republic of Ireland with the current
edition of I.S. 813 and the Local Building Regulations
(IE).
C.O.S.H.H.
Materials used in the manufacture of this appliance
are non-hazardous and no special precautions are
required when servicing.
Codes of Practive
Installation should also comply with the following
British Standards Code of Practice:
BS 7593:1992 Treatment of water in domestic
hot water central heating
systems
BS 5546:1990 Installation of hot water supplies
for domestic purposes
BS 5440-1:2000 Flues
BS 5440-2:2000 Air supply
BS 5449:1990 Forced cicrulation hot water
systems
BS 6798:2000 Installation of gas red hot
water boilers of rated input not
exceeding 70kW
BS 6891:1989 Installation of low pressure gas
pipes up to 28mm
BS 7671:2001 IEE Wiring Regulations
BS 4814:1990 Specication for expansion
vessels
BS 5482:1994 Installation of L.P.G.
and in the Republic of Ireland in accordancce with
the following codes of practice:
I.S. 813 Domestic Gas Installations
Avoid installing the boiler where the air inlet can
be polluted by checmical products such as chlorine
(swimming pool area), or ammonia (hair dresser), or
alkalin products (launderette).
Flue
Detailed information on ue assembly can be found
in the “Connecting the Flue” section.
The boiler must be installed so that the ue terminal
is exposed to the free passage of external air at all
times and must not be installed in a place likely to
cause nuisance. It must not be allowed to discharge
into another room or space such as an outhouse or
closed lean-to.
Condensing boilers have a tendency to form a plume
of water vapour from the ue terminal due to the low
temperature of the ue gasses. The terminal should
therefore be located with due regard for the damage
or discolouration that may occur to building within
the vicinity and consideration must also be given to
adjacent boundaries, openable windows should also
be taken into consideration when siting the ue.
11
installation
NOTE: THE FLUE MUST NOT BE INSTALLED IN A PLACE LIKELY TO
CAUSE A NUISANCE AND POSITIONED TO ENSURE THAT PRODUCTS
OF COMBUSTION DO NOT DISCHARGE ACROSS A BOUNDARY
It may be necessary to protect the terminal with
a guard, if this is the case it will be necessary to
purchase a stainless steel terminal guard. Reference
should be made to the Building Regulations for
guidance.
Ventilation
The room in which the boiler is installed does not
require specic ventilation. If the boiler is installed
in a cupboard or compartment ventillation is not
required for cooling purposes.
Gas Supply
The gas installation and tightness testing must be
in accordance with the requirements of BS6891.
Ensure that the pipe size is adequate for demand
including other gas appliances on the same supply.
Electrical Supply
The appliance requires an earthed 230V - 50 Hz
supply and must be in accordance with current
I.E.E. regulations. It must also be possible to be
able to completely isolate the appliance electrically.
Connection should be via a 3 amp douple pole
fused isolating switch with contact separation of
at least 3mm on both poles. Alternatively, a fused
3 Amp, 3 pin plug and unswitched socket may be
used, provided it is not used in a room containing
a bath or shower, it. It shoild only supply the
appliance.
Water Supply
The boiler is suitable for sealed systems only. The
maximum working pressure for the appliance is
6 bar. All ttings and pipework for the appliance
should be of the same standard. If there is
a possibility of the incoming mains pressure
exceeding 6 bar, particularly at night, then a suitable
pressure limiting valve must be tted.
The boiler is designed to provide hot water on
demand to multiple outlets within the property.
If there is a requirement for greater demands, for
example if the boiler has several bathrooms and
cloakrooms, a vented or unvented hot water storage
system may be used.
Showers
Any shower valves used with the appliance should
be of a thermostatic or pressure balanced type.
Refer to the shower manufacturer for performance
guidance and suitability.
- A Directly below an opening, window, etc 300 mm
- B Horizontally to an opening, window, etc 300 mm
- C Below gutters, soils pipes or drain pipes 75 mm
- D Below eaves 200 mm
- E From vertical drain pipe or soil pipe 75 mm
- F From internal or external corner 300 mm
- G Above ground, roof or balcony level 300 mm
- H From a surface facing the terminal 2500 mm
- I From a terminal facing a terminal 2500 mm
- J Vertically from a terminal on the same wall 1500 mm
- K Horizontally from an terminal on the same wall 300 mm
- L Fixed by vertical ue terminal
The minimum acceptable clearances are shown below:
12
installation
Flushing and Water Treatment
The boiler is equipped with a stainless steel heat
exchanger.
The detailed recommendations for water treatment
are given in BS 7593:1992 (Treatment of water in
domestic hot water central heating systems); the
following notes are givent for general guidance;
If the boiler is installed on an existing system, any
unsuitable additives must be removed.
Under no circumstances should the boiler be red
before the system has been thoroughly ushed;
the ushing procedure must be in line with BS
7593:1992.
We highly recommend the use of a ushing
detergent appropriate for the metals used in the
circuit. These include cleansers produced by Fernox
BetzDearbon, whose function is to disolve any
foreign matter that may be in the system;
In hard water areas or where large quantities of
water are in the system the treatment of water to
prevent premature scaling of the main exchanger is
necessary.
The formation of scale strongly compromises
the eciency of the thermic exchanger because
small areas of scale cause a high increase of the
temperature of the metallic walls and therefore add
to the thermal stress of the heat exchanger.
Demineralised water is more aggressive so in this
situation it is necessary to treat the water with an
appropriate corrosion inhibitor.
Any treatment of water by additives in the system
for frost protection or for corrosion inhibition has
to be absolutely suitable for all metals used in the
circuit.
The use of a corrosion inhibitor in the sysem such
as Fernox MB-1, BetzDearborn Sentinel X100 or
Fernox System Inhibitor is recommended to prevent
corrosion (sludge) damaging the boiler and system;
If anti-freeze substances are to be used in the
system, check carefully that they are compatible
with the metals used in the circuit.
MTS suggests the use of suitable anti-freeze
products such as Fernox ALPHI 11, which will
prevent rust and incrustation taking place.
Preiodically check the pH balance of the water/antifreeze mixture of the boiler circuit and replace it
when the amount measured is out of the range
stipulated by the manufacturer (7 < pH < 8).
DO NOT MIX DIFFERENT TYPES OF ANTI-FREEZE
In under-oor systems, the use of plastic pipes
without protection against penetration of oxygen
through the walls can cause corrosion of the
systems metal parts (metal piping, boiler etc),
through the formation of oxides and bacterial
agents.
To prevent this problem it is necessary to use pipes
with an “oxygen proof barrier”, in accordance with
standards DIN 4726/4729. If pipes of this kind are
not used, keep the system separate by installing
heat exchangers of those with a specic system
water treatment.
IMPORTANT
Failire to carry out the water treatment procedure
will invalidate the appliance guarantee.
System Controls
The boiler is electrically controlled and is suitable
for most modern electronic time and temperature
controls. The addition of such external controls
can be benecial to the ecient operation of the
system. The boiler connections for external contols
are 12V DC and so only controls of 12V DC that have
voltage free contacts should be used. (page 26).
MTS supply a range of wired and wireless system
controls. Contact your supplier for more details.
Location
The boiler can be installed on any suitable internal
wall (suitable sound proong may be required when
installing onto a stud partition wall). Provision
must be made to allow for the correct routing of
the ue and siting of the terminal to allow the
safe and ecient removal of the ue products. A
compartment or cupbaord may be used provided
that it has been built or modied for this purpose. It
is not necessary to provide permanent ventillation
for cooling purposes. Detailed recommendations
are given in BS 5440 Part 2. If it is proposed that it
is to be installed in a timber framed building then
reference should be made to British Gas Document
DM2, IGE/UP/7 or advice sought from CORGI.
Where a room sealed appliance is installed in a
room containing a bath or shower, the appliance
and any electrical switch or appliance control,
utilising mains electricity should be situated
specically in accordance with current IEE Wiring
Regulations.
For unusual locations, special procedures may be
necessary. BS 6798:2000 gives detailed guidance
on this aspect.
13
installation
Condensate Discharge
The condensate discharge hose from the boiler
must have a continuous fall of 2.5o and must be
inserted by at least 50mm into a suitable acid
resistant pipe - e.g. plastic waste or overow
pipe. The condensate discharge pipe must have
a minimum diameter of 22mm, must have a
continuous fall and preferably be installed and
terminated to prevent freezing.
The discharge pipe must be terminated in a suitable
position:
i) Connecting into an internal soil stack (at least
450mm above the invert of the stack). A trap giving
a water seal of at least 75mm must be incorporated
into the pipe run, there also must be an air beak
upstream of the trap.
ii) Connecting into the waste system of the
building such as a washing maching or sink trap.
The connection must be upstream of the washing
machine/sink. If the connection is down stream of
if the waste trap then an additional trap giving a
minimum water seal of 75mm and an air break must
be incorporated in the pipe run, as above.
iii) Terminating into a gully, below the grid level
but above the water level
iv) Into a soakaway
Note: If any condensate pipework is to be installed
externally then it should be kept to a minimum and
be insulated with a waterproof insulation and have
a continuous fall. The total length of external pipe
used should not exceed 3 metres.
Some examples of the type of condensate
terminations can be found below.
1. Internal termination of codensate drainage pipe
to internal stack.
2. External terminaton of condensate drainage pipe
via internal discharge branch (e.g. sink waste) and
condensate siphon.
3. External termination of condensate drainage
pipe via internal discharge branch (e.g. sink waste
- proprietary tting).
4. External termination of condensate drainage pipe
via condensate siphon
14
installation
Installing the Boiler
Please check that you are familiar with the
installation requirement before commencing work
(pages 7 - 13).
The installation accessories described in the
following list are included in the boiler packaging:
- Hanging bracket
- A paper template (showing the dimensions of
the boiler with 5 mm side clearances)
- Connection valves (Compression)
- Screws and washers
- Filling loop
- Installation, Servicing and Operating Instructions
- Flue gasket
Method of positioning the boiler on the wall
The paper template can be used to ensure the
correct positioning of kitchen cabinets etc.
The paper template has to be xed to the wall and
used to locate the position of the hanging bracket
and the centre for the ue hole.
Drill and plug the wall and secure the hanging
bracket using the screws provided. Remove the
boiler from it’s packaging and remove the front
casing panel.
Place the boiler on the hanging bracket.
N
OTE: THE APPLIANCE MUST NOT BE FITTED ON A COMBUSTIBLE
WALL SURFACE.
Connecting the Boiler to the System
- Remove the boiler casing as described on page 15
- Remove the caps and connect the valves to the
boiler using the washers provided;
- 4 x bre washers for the CH ow and return, cold
water inlet and hot water outlet connections;
Safety Valve Discharge and Condense Outlet
The pressure relief valve tube is made of copper. It
should terminate below the boiler safely outside
the premises. Care should be taken that it does
not terminate over an entrance or window or
where a discharge of heated water could endanger
occupants or passers by.
Fill the central heating and DHW system and
bleed air from the system as described in the
Commissioning instructions (page 26).
The system should be carefully checked for
leaks, as frequent relling could cause premature
system corrosion or unnecessary scaling of the
heat exchanger. The pipe from the trap should be
connected to a drain as described in the relevant
regulations.
Pay special attention not to bend the condensate
silicone drain pipe is such a way as to interrupt the
ow. Please only use drain pipe material compatible
with condensate products (refer to BS 6798:2000).
The condensate ow can reach 2 litres/hour because
of the acidity of the condensate products (Ph close
to 2), take care before operation.
See page 13 for condensate discharge possibiities.
Note: Connections viewed from behind boiler
A
A
- remove the 2 screws A from
the transport bar
- dispose of the transport bar
and reassemble the xing
screws.
15
installation
Gas connection
Make sure, using the labels on the packaging and the
data plate on the appliance itself, that the boiler is
in the correct country and that the gas category for
which the boiler was designed corresponds to one of
the categories available in the country where it will
be used.
The gas supply piping must be created and measured
out in compliance with specic legal requirements
and in accordance with the maximum power of the
boiler; you should also make sure that the shuto valve is the right size and that it is connected
correctly.
Check that the supplied gas corresponds to the type
of gas for which the boiler was designed (see the
data plate located on the appliance itself).
It is also important to check that the pressure of
the gas (methane or LPG) you will be using to feed
the boiler is suitable, because if it is insucient the
power may be reduced, causing inconvenience for
the user.
Water connection
The illustration shows the connections for the
water and gas attachments of the boiler. See valves
conguration on page 14.
Check that the maximum water mains pressure does
not exceed 6 bar; if it does, a pressure reducing valve
must be installed.
For the measuring of the pipes and of the heating
bodies in the heating system, the residual head value
should be calculated as a function of the requested
ow rate, in accordance with the values shown in the
circulation pump graph.
Instructions for opening the casing and performing
an internal inspection
Before performing any work on the boiler, rst
disconnect it from the electrical power supply using the
external bipolar switch removing the fuse and shutting
o the gas valve.
To access the inside of the boiler, the following is
necessary:
1.
Remove the casing by unhooking it from the control
panel (a)
2. Loosen the two screws on the front casing (b), pull it
forwards and unhook it from the upper pins (c)
3. Lower the control panel (d)
4. Unhook the two clips on the combustion chamber
panel and lift o (e).
A
B
C
D
E
I
H
F
A. Central heating Flow
B. Domestic Hot Water Outlet
C. Gas Inlet
D.
Domestic Cold Water Inlet
E. Central Heating Return
F. Safety Valve Discharge
H. Drain Valve
I. Drain condensate
(b)
(d)
(a)
(e)
(c)
16
installation
To calculate the size of the heating installation, refer
to the "Available pressure" graph below.
Graph representing the available circulation pump
pressure T20oC
Before the rst time the equipment is used,
the trap must be lled with water. To do this,
add approximately 1/4 litre of water via the
ue outlet before tting the ue system, or
unscrew the cap on the trap positioned underneath the boiler, ll it with water and ret it
Warning! insucient water in the trap can
temporarily cause the ue gas to be expelled
into the surrounding ambient air
Underoor heating
For appliances with underoor heating, t a safety
thermostat onto the underoor heating outlet. For
the electrical connection of the thermostat see the
section on “Electrical connections - page 26”.
If the outlet temperature is too high, the boiler will
stop both domestic hot water and the heating pro-
duction and the error code 116 “oor thermostat
contact open” will appear on the display. The boiler
will restart when the thermostat is closed during
automatic resetting.
If the thermostat cannot be installed, the underoor
heating equipment must be protected by a thermostatic valve, or by a by-pass to prevent the oor from
reaching too high a temperature.
Water circuit diagram
A
B
C
D
E
I
G
H
F
1
4
3
11
8
10
12
14
15
16
17
18
19
20
21
22
7
6
5
A B C D E
1. Manual air vent
3.
Burner
4.
Detection electrode
5.
C.H. ow temperature probe
6.
C.H. return temperature probe
7.
Secondary heat exchanger
8. C.H. pressure relief valve
10. By-pass
11.
Drain valve
12. Condensate trap
14.
C.H. circuit lter
15.
D.H.W. Flow switch
16.
diverter valve
17.
water pressure sensor
18.
circulation Pump
19. expansion vessel
20.
modulating Fan
21.
ignition electrodes
22. thermal fuse
0
50
100
150
200
250
300
350
400
450
500
0 100 200 300 400 500 600 700 800 900 1000 1100 1200
mbar
l/h
24 kW
30-35 kW
30-38 kW
17
installation
Connecting the Flue
Flue System
The provision for satisfactory ue termination must be made as described in BS
5440-1.
The appliance must be installed so that the
ue terminal is exposed to outdoor air.
The terminal must not discharge into
another room or space such as an outhouse
or lean-to.
It is important that the position of the
terminal allows a free passage of air across it
at all times.
The terminal should be located with due
regard for the damage or discolouration that
might occur on buildings in the vicinity, it
must also be located in a place not likely to
cause nuisance.
In cold or humid weather water vapour may
condense on leaving the ue terminal.
The eect of such “steaming” must be considered.
If the terminal is less than 2 metres above a
balcony, above ground or above a at roof to
which people have access, then a suitable stainless steel terminal guard must be tted.
The minimum acceptable spacing from the terminal to obstructions and ventilation openings
are specied in Fig. 1.
Fig. 1
- A Directly below an opening, window, etc 300 mm
- B Horizontally to an opening, window, etc 300 mm
- C Below gutters, soils pipes or drain pipes 75 mm
- D Below eaves 200 mm
- E From vertical drain pipe or soil pipe 75 mm
- F From internal or external corner 300 mm
- G Above ground, roof or balcony level 300 mm
- H From a surface facing the terminal 2500 mm
- I From a terminal facing a terminal 2500 mm
- J Vertically from a terminal on the same wall 1500 mm
- K Horizontally from an terminal on the same wall 300 mm
- L Fixed by vertical ue terminal
118 mm
See table
118 mm
4
See table on page 23
180
Fig. 2
18
installation
Warning
The exhaust gas ducts must not be in contact with or close to inammable material and must not pass through building structures or walls made of inammable material.
When replacing an old appliance, the ue system must be changed.
Important
Ensure that the ue is not blocked.
Ensure that the ue is supported and assembled in accordance with these instructions.
150 mm
118
* pente 5 mm par mètre
150 mm
* pente
Installation without extension
Installation with extension
slope 5 mm per metre
Level
Level
slope
Fig. 3
Fitting the Coaxial Flue
(Ø 60 / 100 Horizontal)
Contents:
1x Silicone O-Ring (60mm)
1x Elbow (90°)
2x Wall Seals (Internal & External)
1x Flue Pipe including Terminal (1 metre - 60/100)
2x Flue Clamps
4x Screws
2x Seals
Once the boiler has been positioned on the wall, t
the rubber ue seal into the internal ue turret (see
diagram opposite),
insert the elbow into the socket and rotate to the
required position. note: It is possible to rotate the
elbow 360° on its vertical axis.
Using the ue clamp, seals and screws supplied (Fig
4) secure the elbow to the boiler.
The 1 metre horizontal ue kit (3318073) supplied is
suitable for an exact X dimension of 753mm.
Measure the distance from the face of the external
wall to the face of the ue elbow (X - Fig 2), this
gure must now be subtracted from 753mm, you
now have the total amount to be cut from the plain
end of the ue.
Draw a circle around the outer ue and cut the ue
to the required length taking care not to cut the
inner ue, next cut the inner ue ensuring that the
length between the inner and outer ue is maintained. (Fig 4).
e.g.
X = 555mm
753-555 = 198mm (Length to be cut from the
plain end of the ue).
Once cut to the required length, ensure that the ue
is free from burrs and reassemble the ue. If tting
the ue from inside of the building attach the grey
outer wall seal to the ue terminal and push the
ue through the hole, once the wall seal has passed
through the hole, pull the ue back until the seal
is ush with the wall. Alternatively, the ue can be
installed from outside of the building, the grey outer
seal being tted last.
Should the ue require extending, the ue connections are push t, however, one ue bracket should
be used to secure each metre of ue.
Note: See table for maximum and minimum ue
runs.
19
installation
Clamp
Seal
Screws
Once the boiler has been positioned on the wall, it is necessary to insert the Ø80/125 adaptor (Fig. 5) for both
horizontal and vertical ue runs into the boiler ue socket (not supplied with ue kit - Part No 3318095).
Push the adaptor onto the boilers ue connection,
grease the seals then add extensions or elbows as required, secure the adaptor, using the clamp and screws
provided.
To t extensions or elbows it is rst necessary to ensure that the lip seal is tted correctly into the inner
ue, once veried, it is simply necessary to push them
together, no clamps are necessary to secure the ue
components.
Before proceeding to t the ue, ensure that the maximum ue length has not been exceeded (See the
tables) and that all elbows and bends have been taken
into consideration, the maximum ue length is 10 metres, for each additional 90° elbow 1 metre must be subtracted from the total ue length, and for each 45° 0.5
metres must be subtracted from the total ue length
(the height of the vertical adaptor and a 45° bend can
be seen in Fig.6 and a 90° bend in Fig. 7).
Note: DO NOT cut the vertical ue kit.
180 mm
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fitting the 5” Flue (Ø 80 / 125 Horizontal/vertical)
20
installation
Fitting the Coaxial Flue (Ø 60 / 100 Vertical)
Note: See table for maximum and minimum ue
runs.
Contents:
1x Silicone O-Ring (60mm)
1x Conical Adaptor (60/100mm)
1x Vertical Flue Kit (80/125mm)
3x Screws
The vertical ue kit is supplied with a specially designed weather proof terminal tted, it can be used
either with a at roof or a pitched roof.
The Vertical ue kits useable lengths with the
pitched roof ashings are indicated in Fig. 7.
Before proceeding to t the ue, ensure that the
maximum ue length has not been exceeded (See
the tables) and that all elbows and bends have been
taken into consideration, the maximum ue length
is see table, for each additional 90° elbow 1 metre
must be subtracted from the total ue length, and
for each 45° 0.5 metres must be subtracted from the
total ue length (the height of the vertical adaptor
and a 45° bend can be seen in Fig. 8).
Mark the position of the ue hole in the ceiling
and/or roof (see Fig. 7 for distance from wall to the
centre of the ue).
Cut a 130mm diameter hole through the ceiling
and/or roof and t the ashing plate to the roof.
DO NOT cut the vertical ue kit.
To connect the vertical ue kit directly to the boiler,
place the vertical starter kit (Part No. 3318079) (see
Fig. 7) onto the exhaust manifold and secure with
the clamp, t the vertical adaptor onto the vertical
starter kit (note: there is no need to use a clamp to
secure this as it is a push t connection), the vertical
ue kit must then be inserted through the roof
ashing, this will ensure that the correct clearance
above the roof is provided as the terminal is a xed
height.
Should extensions be required, they are available in 1 metre (Part No. 3318077), 500mm (Part
No. 3318078) and 160mm lengths, they must be
connected directly to the vertical starter kit before
connecting the adaptor to allow the vertical ue kit
to be tted. In the event that extension pieces need
to be shortened, they must only be cut at the male
end and it must be ensured that the inner and outer
ue remain ush.
When utilising the vertical ue system, action
must be taken to ensure that the ue is supported
adequately to prevent the weight being transferred
to the appliance ue connection by using 1 ue
bracket per extension.
When the ue passes through a ceiling or wooden
oor, there must be an air gap of 25mm between
any part of the ue system and any combustible
material. The use of a ceiling plate will facilitate this.
Also when the ue passes from one room to another
a re stop must be tted to prevent the passage of
smoke or re, irrespective of the structural material
through which the ue passes.
180 mm
Fig. 7
Fig. 8
21
installation
Fitting the Twin Pipe (Ø80 / 80)
Note: See table for maximum and minimum ue
runs.
Where it is not possible to terminate the ue within
the distance permitted for coaxial ues, the twin
ue pipe can be used by tting a special adaptor to
the ue connector and using the aperture for the air
intake located on top of the combustion chamber.
Always ensure that the ue is adequately supported,
using one ue bracket per extension and avoiding
low points. (MTS supply suitable clamps as Part No.
705778).
To utilise the air intake it is necessary to:
1) Take the air intake cover o the top of the appliance
2) Assemble the ange on the header supplied with
the boiler
3) Insert the header on the tube or the elbow up
until the lower stop (you do not have to use the
washer).
4) Insert the elbow/header in the boiler air intake
hole and fasten it with screws.
The twin ue pipes can be tted with or without additional elbows and need no clamps, simply ensure
that the red o-ring is inserted in the female end of
the ue pipe and push the extension piece fully into
the previous section of ue pipe or elbow, check
that the o-ring is not dislodged when assembling
the ue (greasing the seal will aid assembly).
Twin pipe can also be converted back to Coaxial ue
to enable vertical termination with a coaxial kit by
using the pipe bridge (Twin - Coaxial Adaptor - Part
No. 3318089). When running the twin ue pipe
vertically.
It is not possible to terminate concentrically horizontally. Termination is only possible with separate
air and exhaust terminals.
When siting the twin ue pipe, the air intake and
exhaust terminals must terminate on the same wall,
the centres of the terminals must be a minimum of
280 mm apart and the air intake must not be sited
above the exhaust terminal (refer to Fig. 10). The
air intake pipe can be run horizontally, however,
the terminal and the nal 1 metre of ue must be
installed either horizontally or with a slight fall away
from the boiler to avoid rain ingress.
It is also strongly recommended that the air intake
pipe run be constructed of insulated pipe to prevent
condense forming on the outside of the tube.
The maximum permissible ue length for twin ue
is dependent on the type of run used (see table on
page 23).
For further information relating to ue runs not
illustrated, please contact the Technical Department
on 0870 241 8180.
22
installation
For coaxial systems, the maximum development
value, mentioned in the table below also takes into
account an elbow.
For twin ue systems the maximum development
value, mentioned in the table includes the exhaust
gas/air intake terminal.
Type 5 outlets should respect the following instructions:
1- Use the same ø 80 mm ue pipes for the air
intakes and exhaust gas ducts.
2- If you need to insert elbows in the air intake and
exhaust gas ducts, you should consider for each
one the equivalent length to be included in the
calculation of developed length.
3- The exhaust gas duct should jut above the roof by
at least 0.5 m.
4- The intake and exhaust gas ducts in Type C13 +
C53 must be installed on the same wall, or where
the exhaust is vertical and the air intake horizontal, the terminals must be on the same side of the
building.
EXHAUS T
AIR IN TAKE
AIR IN TAKE
AIR IN TAKE MUS T NO T BE
FITTED ABOVE THE EXHAUS T
195
105
120
180
Fig. 9
Fig. 10
23
installation
Table of ue gas exhaust duct lengths
COAXIAL SYSTEM
FLUE TYPE
MAX
LENGTH
DIAMETER of
PIPE
C13
Flue gas exhaust and air suction
duct through external wall in the
same range of pressure
24
12 m
36 m
60/100
80/125
30
10 m
30 m
60/100
80/125
38
6 m
18 m
60/100
80/125
C 33
Flue gas exhaust and air suction
duct from outside with roof
terminal in the same range of
pressure
24
12 m
42 m
60/100
80/125
30
10 m
35 m
60/100
80/125
38
8 m
21 m
60/100
80/125
C43
Individual or shared ue gas
exhaust and air suction through
ue ducting built into the building
24
12 m
0 m
60/100
80/125
30
10 m
0 m
60/100
80/125
38
8 m
0 m
60/100
80/125
24
installation
TWIN-PIPE SYSTEM
FLUE TYPE
MAX
LENGTH
DIAMETER of
PIPE
C13
Flue gas exhaust and air suction
duct through external wall in the
same range of pressure
24
36 m
(S1=S2)
80/80
30
30 m
(S1=S2)
38
18 m
(S1=S2)
C 33
Flue gas exhaust andair suction
duct from outsidewithroof
terminalin the same range of
pressure
24
60 m
(S1=S2)
80/80
30
50 m
(S1=S2)
38
21 m
(S1=S2)
C53
Flue gas exhaust leading outside
and air suction duct through
external wall not in the same range
of pressure
24
84 m
(S1+S2)
80/80
30
70 m
(S1+S2)
38
42 m
(S1+S2)
S1 = Air intake S2 = Flue gas exhaust
S1 = S2 - Air intake and ue gas exhaust equal lengths
S1 + S2 - Air intake and ue gas exhaust unequal lengths
25
installation
WARNING
Before performing any work on the boiler,
rst disconnect it from the electrical power
supply using the external bipolar switch and
remove the fuse.
Electrical connections
For increased safety, ask a qualied technician to
perform a thorough check of the electrical system.
The manufacturer is not responsible for any damage
caused by the lack of a suitable earthing system or by
the malfunctioning of the electricity mains supply.
Make sure that the system is able to withstand the
maximum power absorbed by the boiler (this is
indicated on the appliance data plate). Check that
the section of the wires is suitable and is not less 0,75
mm2
The appliance must be connected to an eecient
earthing system if it is to operate correctly.
The power supply cable must be connected to a
230V-50Hz network, where the L-N poles and the
earth connection are all respected.
Important!
In the event that the power supply cable must
be changed, replace it with one with the same
specications.
Power supply cable
Important!
The appliance is supplied with a y-lead
already connected, this must be connected
to a 240V supply fused at 3 Amp and must
facilitate completed electrical isolation of
the appliance, by use od a fused double
pole isolator having a contact separation
of at least 3mm in all poles or alternatively
by means of a 3A fused three pin plug and
unswitched shuttered socket outlet both
complying with BS1363.
The use of multiplugs, extension leads or adaptors is
strictly prohibited.
It is strictly forbidden to use the piping from the
hydraulic, heating and gas systems for the appliance
earthing connection.
The boiler is not protected against the eects caused by
lightning. If the mains fuses need to be replaced, use 2A
rapid fuses.
Peripheral unit connection
To access peripheral unit connections carry out the
following steps:
- Disconnect the boiler from the power supply
- Remove the casing by unhooking it from the
instrument panel
- Rotate the control panel while pulling it forwards
- Unscrew the three screws on the back cover of
the instrument panel
- Unhook the right side clip and the right front clip;
then lift the ap
The terminal board (see gure) may be accessed in order
to connect:
Outdoor sensor
Room thermostat 1
Optional P.C.B.s can also be installed for further
accessories:
BUS P.C.B. Clima Manager
Modulating Room Sensor
Programmable Room Thermostat
Outdoor Sensor
- other plugs: for managing multi-zones
multitemperatures, Solar kit,
etc...
Caution!
For the connection and positioning of the
wires belonging to optional peripheral
units, please refer to the installation manuals of these units.
H05V2V2-F
120
140
26
installation
Room Thermostat / Remote Clock Connection
To connect a room thermostat, it is necessary to:
1. Open the control panel
2. Loosen the cable clamp using a screwdriver
and insert the wires leading from the room
thermostat
3. Connect the wires to the terminals as indicated in
the gure below, removing the link
4. If a remote time clock is to be tted, using a volt
free switching time clock connect the switching
wires from the time clock following points 1 - 3
above
5. If using an external time clock and room
thermostat, these must be connected in series as
shown in diagram C,
6. Ensure that they are well connected and not
subject to stress when the control panel is closed
NOTE: WHEN CONNECTING THE BOILER TO EXTERNAL CONTROLS,
DO NOT RUN 240V CABLES AND CABLES FOR SWITCHING
CIRCUITS (WHICH ARE LOW VOLTAGE) TOGETHER, USE SEPERATE
CABLES TO PREVENT INDUCED VOLTAGE ON THE LOW VOLTAGE
CIRCUITS.
CARTE CHAUDIERE
ACO-GAL1
Transmetteur BUS
(Optionnel)
Emplacement
carte optionnelle
SE
TA
TP/
Connector TA on PCB
(low voltage switching)
Connector TA on PCB
(low voltage switching)
Connector TA on PCB
(low voltage switching)
27
installation
Electrical diagram
For increased safety, ask a qualied technician to perform a thorough check of the electrical system.
The manufacturer is not responsible for any damage caused by the lack of a suitable earthing system or by the
malfunctioning of the electricity mains supply.
8
1
Connessione
sonda solare
5
1
ON
Display
Display
1 8
Flussimetro
sanitario
Elettrodo
Rilevazione
Ventilatore
AccenditoreValvola gas
Valvola dev.
motorizzata
L N
FAN
VALVOLA
GAS
ACCENDITORE
EARTH
FLAME
FLOW
PUMP
ZONE1
FILLING
PUMP
SPEED
1
1
FUSE 2AT
1 2 3 4 1 2 3 45 6
Circolatore
6
1
1
234
Termostato
Ambiente
Sonda NTC
mandata risc.
CN04
CN04
CN07
CN22
CN22
Pressostato
di minima
Sonda NTC
ritorno risc.
Term. protezione
scambiatore
P
13 12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
11 10 9 8 7 6 5 4 3 2 1
11 10 9 8 7 6 5 4 3 2 1
2
1
8 7 6 5 4 3 2 1
Termostato
sovratemperatura
ignitor
detection
electrode
gas
valve
display
room
thermostat
circulation
pump
diverter valve
C.H. ow temp.
probe
thermal fuse
modulating fan
C.H. return temp.
probe
D.H.W ow
switch
Switch on/o
28
commissioning
Initial preparation
MT S (G B) L imi ted sup por t the ben chm ark
initiative. On pages pages 65 and 66 of this
manual the Benchmark Commissioning Checklist
and Service interval Record can be found. It is
important that this is completed in the presence
of your customer, they are shown how to use it,
and it is signed by them. Please instruct your
customer that they must have this manual with
them whenever they contact a service engineer
or us.
Preliminary electrical system checks to ensure
elec trical sa fety m ust be car ried o ut b y a
competent person i.e. polarity, earth continuity,
resistance to earth and short circuit.
Electricity supply
- Check that the voltage and frequency of the
electricity supply correspond to the data shown
on the boiler data plate;
- Make sure that the earthing connection is
ecient.
Filling the Heating System:
Switch the electrical supply to the boiler on in
order to view the system pressure on the display;
Remove the front casing panel and lower the
control panel as described on page 13).
Open the central heating flow and return cocks
supplied with the connection kit;
Lift the cap on the automatic air release valve
and leave open permanently;
Close all air release valves on the central heating
system;
Gradually open the valves at the filling point
(filling loop) until water is heard to flow, do not
open fully;
Open ea ch air rele ase tap startin g with the
lowest point and close them only when clear
water free of air is visible;
Purge the air from the pump by unscrewing the
pump plug anti-clockwise, also manually rotate
the pump shaft in the direction indicated by the
pump label to ensure the pump is free;
Refit the pump plug;
Continue filling the system until at least 1.5 bar
registers on the pressure gauge;
Inspect the system for water tightn ess and
remedy any leaks discovered.
IMPORTANT!
MANUALLY VENT THE HEAT EXCHANGER AT THE MANUAL AIR
VENT. FAILURE TO VE NT ADEQ UATELY MAY DAMAGE THE
HEAT EXCHANGER (PAGE 7, LEGEND 2).
Filling of the DHW System:
Close all hot water draw off taps;
Open the cold water inlet cock supplied with the
connection kit;
Slowly open each draw off tap and close them
only when clear water, free of bubbles, is visible.
Gas Supply:
Inspect the entire installation inc ludin g the
gas meter and test for tightness. The entire
installation should be in accordance with the
relevant standards. In GB this is BS 6891 and in
IE this is the current edition of I.S.813.
The connection on the the appliance is a 15mm
nut and olive located at the rear of the gas
service cock.
If the gas supply serves other appliances, ensure
that an adequate supply is available both to the
boiler and the other appliances when they are in
use at the same time.
Pipe work must be of an adequate size. Pipes
of less than 22mm should not be used, final
connection being 15mm.
Open the gas cock (supplied with the connection
kit ) to the app lia nce and che ck the gas
connection on the appliance for leaks.
Water Treatment:
The boiler is equipped with a stainless steel heat
exchanger.
Th e d eta ile d r ecomm end ati ons fo r w ate r
treatment are given in BS 7593:1992 (Treatment
of water in domestic hot water central heating
syste ms); the followi ng notes are gi ven fo r
general guidance;
If the boiler is installed on an existing system, any
unsuitable additives must be removed;
Under no circumstances should the boiler be
fired before the system has been thoroughly
flushed; the flushing procedure must be in line
with BS7593:1992.
Fir stly fil l th e central heat in g system with
the power off, and flush through cold, fill the
central heating system again, adding a flushing
detergent, run the boi ler on central heating
until it reaches its operating temperature and
flush the system, refill the system with a suitable
corrosion inhibitor,
NOTE: FAILURE TO CARRY OUT THE FLUSHING PROCEDURE WILL
RESULT IN THE WARRANTY BECOMING VOID.
29
commissioning
FIRST IGNITION OPERATION
1. Check the electrical supply.
Complete . . . . . . . . . . . . . . . . . . .
Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installer . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Check the type of gas and
change the gas if necessary.
Complete . . . . . . . . . . . . . . . . . . .
3. Check the gas tightness.
Complete . . . . . . . . . . . . . . . . . . .
4. Measure the gas inlet.
Complete . . . . . . . . . . . . . . . . . . .
5. Check the exhaust fume.
See section….
Complete . . . . . . . . . . . . . . . . . . .
6. Fill the installation. See
section….
Complete . . . . . . . . . . . . . . . . . . .
7. Check the hydraulic water
tightness.
Complete . . . . . . . . . . . . . . . . . . .
8. Spin the pump.
Complete . . . . . . . . . . . . . . . . . . .
9. Set the heating power. See
section….
Complete . . . . . . . . . . . . . . . . . . .
10. Adapt the regulation at
the heating installation.
Complete . . . . . . . . . . . . . . . . . . .
11. Balance the central
heating circuit.
Complete . . . . . . . . . . . . . . . . . . .
12. Check the working in DHW
mode.
Complete . . . . . . . . . . . . . . . . . . .
13. Adjust DHW ow rate on
the boiler (if necessary).
Complete . . . . . . . . . . . . . . . . . . .
14. Make a combustion rate
with once pressing on
RESET button during 5 sec.
Complete . . . . . . . . . . . . . . . . . . .
15. Check the ionisation
current.
Complete . . . . . . . . . . . . . . . . . . .
6. Explain to the end user the
working of the boiler.
Complete . . . . . . . . . . . . . . . . . . .
30
commissioning
Ignition procedure
Press the ON/OFF button on the control panel to
switch on the boiler.
Electricity supply
- Check that the voltage and frequency of the
electricity supply correspond to the data shown
on the boiler data plate;
- Make sure that the earthing connection is
ecient.
First ignition
1. Make sure that:
- The gas valve is closed;
- The electrical connection has been properly
carried out. Make sure that, in any case, the
green/yellow earthing wire is connected to an
ecient earthing system;
- Use a screwdriver to lift the cap on the automatic
air relief valve;
- Switch on the boiler (by pressing the ON/OFF
button), the green led 3 will illuminate indicating
that the boiler is ready to operate. Turn the CH
buttton 5 between min. and max position. The
pump will start and the burner will atemp to light,
after 7 seconds the boiler will look out because
there is no gas; the red Led 8 illuminates.
- Bleed the air from the radiators;
- The exhaust duct for combustion products should
be suitable and free from any obstructions;
- Any necessary ventilation inlets in the room
should be open (type B installation).
2. Open the gas cock and check the connection
seals, including the boiler connection joints,
making sure that the meter does not detect any
passage of gas. Eliminate any leaks.
3. Unlock the boiler by pushing on thr reset button.
The burner light, if the rst start fail, repend the
operation until the burner light.
90°40°
50°
60° 70°
80°
on/o
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
9
6
12
I
31
commissioning
SETTING
Maximum CH power and soft ignition
setting
1. Push ON/OFF button for 10 secondes, the
led red 8 blinks.
2. Adjusting with the CH knob 5 the maxi
CH power between 0 and 99 % (see table)
3. Adjusting with the DHW knob 6 the soft
ignition between 0 and 99 % (see table)
The percentage level is visualized by the
green led 1
4. To store the new values of settings, it’s
enough tu push ON/OFF button.
TAC setting and postcirculation DHW
Tac setting
After the previus phase (10 secondes of
ON/OFF button pressed), pressing RESET
the second level of setting is entered, so
that the green led 8 blinks indicating that
we are in a new regulating stage; Now we
can modify :
- turn the CH knob = TAC (0,1,2,3,4,5,6
minutes, with zero, one or more temperature
leds lit - see table)
Postcirculation DHW setting
- turn the DHW knob at minimum or maximum position
minimum position postcirculation = 0 min
maximum position postcirculation = 3 min
gas setting
24 kW
30 kW
38 kW
G20
G31
G20
G31
G20
G31
lower Wobbe index (15°C, 1013 mbar) (MJ/m3)
45,67
70,69
45,67
70,69
45,67
70,69
gas valve restrictor(ø)
NO
3,80NO4,50NO5,250
gas ow max/min (15°C, 1013
mbar)
(nat - m3/h) (GPL - kg/h)
max D.H.W
2,65
1,94
3,17
2,33
4,02
2,95
max C.H.
2,33
1,71
2,96
2,17
3,28
2,41
min
0,58
0,43
0,69
0,50
0,79
0,58
0 min
3 min
Green Leds
Temperature indicator
Max adjustable power
and soft ignition
= no led lit
● = lit
40 50 60 70 80 90 *
0 to 39 %
●
40 to 49 %
● ●
50 to 59 %
● ● ●
60 to 69 %
● ● ● ●
70 to 79 %
● ● ● ● ●
80 to 89 %
● ● ●
● ●
●
90 to 99 %
* This LED is red
Green Leds
Temperature indicator
TAC
= no led lit
● = lit
40 50 60 70 80 90 *
0 min
●
1 min
● ●
2 min
● ● ●
3 min
● ● ● ●
4 min
● ● ● ● ●
5 min
● ● ●
● ●
●
6 min
* This LED is red
32
commissioning
Test function and combustion analysis
The boiler has two pressure taps to measure the combustion gas temperature, the combustive air and the
concentrations of O2 and CO2 on the outside of the
ue gas header.
to access these pressure taps, unscrew the screw
which holds the blanking cover and its seal together.
Checking the gas setting
To carry out analyses of combustion, the test function must be activated.
Maximum gas ow combustion analysis
Activate the test function at the maximum heating
power, pushing for 5 secondes the RESET until the
yellow led 8 blinks (also 60°C led is lit to indicate
that Chimney is at max. CH absolute) Than rotating
the CH knob to the min., intermediate position and
max position and max. position it’s possible to switch
between min, max CH absolute and max DHW power
(respectively the 40°C, 60°C and 80°C are lit to indicate the power level.
The function is automatically deactivated after 10
minutes or by pressing the RESET button.
Wait for the boiler to stabilise before carrying out the
combustion analyses. Check the CO2 value according
to the table below.
Important: do not remove silencer 20
N.B.: when the front combustion chamber panel
is open, the CO2 value drops by 0.3%.
If the values taken dier from the table, adjust the
gas valve following the procedure described below.
Adjust the CO2 content to
± 0.2 by turning setting
screw 50 (2.5 mm allen key)
- tighten to lower the CO2 value
- unscrew to increase the CO2 value
Set the content by turning the screw about a 1/4 of a
turn then wait after each change for approximately 1
minute for the CO2 value to stabilise, then repeat.
Minimum gas ow combustion analysis
Activate the cleaning function at minimum power in
either heating or domestic hot water production.
Wait for the boiler to stabilise before carrying out the
combustion analyses. Check the CO2 value according
to the table above.
Important: do not remove silencer 20
N.B.: when the combustion chamber is open, the
CO2 value drops by 0.3%.
If the values taken dier from the table, adjust the
gas valve following the procedure described below.
To adjust the CO2 value, remove cap
2, adjust the
CO2 content to ± 0.2 by turning setting screw 51 (4
mm allen key)
- unscrew to lower the CO2 value
- tighten to increase the CO2 value
Set the content by turning the screw about a 1/4 of a
turn then wait after each change for approximately 1
minute for the CO2 value to stabilise, then repeat.
Once the settings and analyses are complete, exit
test mode, and reposition the blanking cover and its
seal correctly.
CO2 massimo e
minimo
243038
CO2 (%)
G20
9,0 ± 0,2
9,0 ± 0,2
9,4 ± 0,2
G31
10,7 ± 0,2
10,0 ± 0,2
10,6 ± 0,2
8
50
2
Only a 4 mm
allen key must be
used. Do not use a
screwdriver
51
Only a 2.5 mm allen key
must be used. Do not
use a screwdriver
33
boiler protection devices
Boiler protection devices
The boiler is protected from malfunctioning by
means of internal checks performed by the electronic
microprocessor P.C.B., which stops the boiler from
operating if necessary.
In the event of the boiler being shut o in this manner,
the leds code show the type of shut-o and the reason
behind it.
There are two types of shut-o:
Safety shut-o
This type of error is “volatile”, which means that the boiler starts up again automatically as soon as the problem
which caused the shut-o is removed; the yellow led 9
blinks and green leds 1 indicating the error code- see
table.
In fact, soon as the cause of the shut-o disappears, the
boiler starts up again and continues to operate normally.
In this case or if the re-balancing request is performed on
a frequent basis, switch the boiler o, turn the external
electric switch to the OFF position, shut o the gas cock
and contact a qualied technician to check for any leaks
of water.
Nota : In the event of insuciente water pressure inside
the heating circuit, the boiler will perform a safety shuto (yellow led 9 blinks - leds 40-50 light – see table). To
re-pressurise the boiler, it will be necessary to connect
the silver exible hose supplied to the two isolating
points underneath the boiler, once the hose is connected, open up both of the black quarter turn handles,
once the pressure reads 1.5 bar on the pressure gauge. If
the pressure drops very frequently, there may be a water
leak at some point in the system. If this is the case please
contact your installer and ask them to check it.
Shutdown
This type of error is “non-volatile”, which means that it is
not removed automatically.
The red led 8 light and green leds 1 indicating the error
code- see table.
To restore normal operation press the button on
the control panel.
Important
If this shutdown occurs frequently, contact an
authorised Technical Service Centre for assistance.
For safety reasons, the boiler will permit a maximum
of 5 resets in 15 minutes (5 presses of the
button).
Anti-frost Device.
The anti-frost function acts on the central heating ow
temperature probe, independently from other regulations, when the electrical supply is turned on.
If the primary circuit temperature is between
3°C and 8°C the pump will run (with the diverter valve switching between central heating and
hot water every 1 minute) until the temperature
reaches > 9°C.
If the ow temperature remains between 3°C and 8°C
the pump will continue to run for a maximum of 20 mi
nutes unless a temperature above > 9°C is detected in
the central heating ow, after this the the burner will
re (heating position) until a temperature of > 30°C is
detected.
If the central heating ow temperature is < 3°C, the burner will re (heating position) at minimum power until
the temperature reaches > 30°C, the burner will go out.
If lockout is caused by overheat the burner will not re
but the pump will continue to run (heating position).
The anti-frost device activates only when (with the boiler
operating correctly):
- the system pressure is correct;
- the boiler is electrically powered;
- there is a supply of gas.
Table summarising error codes
Green Leds
Temperature indicator
Reset
Note
Description ❍ = flashing light
●
= lit
40 50 60 70 80 90 yellow red
● ●
X Overheat
● ● ●
X Insucient circulation
Insucient water (request lling)
C.H. Flow temp. probe circuit open / short circuit
C.H. Return temp. probe circuit open / short circuit
External sensor circuit open / short circuit
Floor Thermostat contact open
● ● ●
X Heating delevery probe problem
Insucient circulation
EEPROM error
Comunication error
Too many (> 5) resets in 15 minutes
● ●
X Main P.C.B. error
Room sensor circuit open / short circuit
●
X No ame detected
Flame detected with gas valve closed
● ● ● ●
X Flame lift
1st Ignition Failed
2nd Ignition Failed
Flame cut-o
● ● ●
X Thermofuse open
● ● ●
X Fan speed error
34
maintenance
Important
Maintenance is an essential part of the safe and
ecient operation of the boiler and ensures its
durability. It should be performed according to the
instructions given in current legislation. Perform
combustion analysis regularly in order to check the
operating eciency of the boiler and to make sure
any polluting substances relased are within the
boudaries set by current legislation.
Before beginning maintenance work:
- Disconnect the appliance from the electricity
supply by turning the external bipolar switch to
the “OFF” position;
- Close the gas valve and the central heating and
domestic hot water system valve.
After the work has been completed the initial settings
will be restored.
General comments
It is recommended that the following inspections be
carried out on the boiler at least once a year:
1. Check the seals in the water part and, if necessary,
replace the gaskets and restore the seal to perfect
working order.
2. Check the seals in the gas part and, if necessary,
replace the gaskets and restore the seal to
perfect working order.
3. Visually check the overall condition of the
boiler.
4. Visually check the combustion and, if necessary,
disassemble and clean the burner.
5. Following the inspection detailed in point
“3”, disassemble and clean the combustion
chamber, if necessary.
6. Following the inspection detailed in point “4”,
disassemble and clean the burner and injector,
if necessary.
7. Cleaning the primary heat exchanger
8. Make sure the following heating safety devices
are operating correctly:
- temperature limit safety device.
9. Make sure that the following gas part safety
devices are operating correctly:
- absence of gas or ame safety device
(ionisation).
10. Check the eciency of the domestic hot water
production process (test the ow rate and
temperature).
11. Perform a general inspection of the boiler
operation.
12. Remove oxide from the detection electrode
using an emery cloth.
13. These checks are not exhaustive. Further
mechanical, electrical and combustion
maintenance checks may be required.
Operational test
After having carried out the maintenance operations,
ll the heating circuit at a pressure of approximately
1.0 bar and release the air from the system.
Fill the domestic hot water system at the same time.
- Begin operating the boiler.
- If necessary, release the air from the heating
system again.
- Check the settings and make sure all the
command, adjustment and monitoring parts are
working correctly.
- Check the ue system is sealed and operating
correxctly.
35
maintenance
Draining procedures
The heating system must be drained using the
following procedure:
- Switch o the boiler, make sure the external
bipolar switch is in the OFF position and shut o
the gas valve;
- Loosen the automatic air relief valve;
- Open the system drain o cock and collect the
escaping water in a container;
- Empty the water from the lowest points of the
system (where applicable).
If the system is to be left inactive in areas where the
room temperature may fall below 0°C during winter,
we recommend that anti-freeze liquid is added to
the water in the heating system in order to avoid the
need for repeated draining; when this liquid is used
make sure it is compatible with the stainless steel
used for the bodywork of the boiler.
We recommend the use of anti-freeze products
which contain PROPYLENE GLYCOLS as these inhibit
corrosion and that they are used in conjunction with
the anti-scaling and anti-corrosion function, in the
quantities suggested by the manufacturer, at the
mimimum temperature.
Regularly check the pH level of the water/anti-freeze
mix in the boiler circuit and replace it when the value
measured is lower than the limit prescribed by the
manufacturer.
DO NOT MIX DIFFERENT TYPES OF ANTI-FREEZE.
The manufacturer will not be held liable for any
damage caused by the appliance or the system due
to the use of inappropriate anti-freeze substances or
additives.
Draining the domestic hot water system and
indirect cylinder
Every time there is a danger of freezing, the domestic
hot water system must be drained as follows:
- Shut o the water mains inlet valve;
- Open all the hot and cold water taps;
- Empty the water from the lowest points of the
system (where applicable).
WARNING
Before handling, empty all components which may
contain hot water, performing bleeding where
necessary.
Descale the components in accordance with the
instructions provided on the safety data leaet
supplied with the product used, make sure the room
is well ventilated, wear protective clothing, avoid
mixing dierent products, and protect the appliance
and surrounding objects.
Seal all openings used to take a gas pressure reading
or to make any gas adjustments.
Make sure that the nozzle is compatible with the
supplied gas.
If a smell of burning is detected or smoke is seen
leaking from the appliance, or there is a smell of gas,
disconnect it from the electricity supply, shut o the
gas valve, open the windows and call for technical
assistance.
Cleaning the primary exchanger
Cleaning the smoke side
The inside of the primary exchanger is accessed by
removing the burner. Wash with water and detergent using a non-metallic rie-type brush, rinse with
water.
Cleaning the siphon
The siphon is accessed by emptying the condensate
bowl located in the bottom section. Wash with
water and detergent.
Replace the condensate collection bowl in its
housing.
NB: in the event of prolonged use of the appliance,
the siphon must be lled before being used again.
A lack of water in the siphon is dangerous and may
cause smoke to be released into the atmosphere.
36
MAINTENANCE GUIDE
1. GENERAL ACCESS
GENERAL ACCESS
Tools
Time
3 min
1
Unclip the cover to remove Remove the two screws Remove the front panel
2
Lower the electrical box
Remove the combustion chamber front panel by releasing the
clips
37
MAINTENANCE GUIDE
2. ELECTRICAL UNIT
2.1 CONTROL BOX ACCESS
CONTROL BOX ACCESS
Tools
Time
4 min
1
Remove the front panel as above
and pivot the electrical box
Remove the two screws and
unlock the four clamps to gain
access to the control box
2.2 FUSE
FUSE
Tools Time
5 min
1
Open the control box as above Remove the fuse
38
MAINTENANCE GUIDE
2.3 MAIN PCB
MAIN PCB
Tools
Time
7 min
1
After opening the control box,
disconnect the electrical plug
connectors
Unscrew the two screws and
remove the PCB
2.4 DISPLAY PCB
DISPLAY PCB
Tools
Time
7 min
1
Unclip the cover to remove
Remove the two control knobs Unscrew the four screws and pull
the assembly towards you
2
Disconnect the electrical plug
connectors, unlock the two
clamps, and remove the PCB
39
MAINTENANCE GUIDE
3. HYDRAULIC UNIT
3.2 3 WAY VALVE
3 WAY VALVE UNIT
Tools Time
5 min
1
Unplug the diverter valve cable
Remove the clip and lift the motor from the
diverter valve body
2
Drain the boiler (see 3.3). Remove the clip and
lift the diverter valve from the assembly
When reassembling, ensure the diverter valve is
aligned correctly
3.1 RIGHT HAND HYDRAULIC BLOCK ASSEMBLY
1
2
3
5
4
6
7
8
9
11
12
13
14
10
LEGEND
1. Diverter valve motor
2. Diverter valve
3. Auto air vent
4. Primary water pressure switch
5. Pump
6. Central heating lter
7. Non return valve
8. Non return valve assembly
9. DHW ow switch assembly
10. Drain valve
11. Central heating return
12. Domestic cold water intlet
13. Domestic hot water outlet
14. Central heating ow
40
MAINTENANCE GUIDE
3.3 DRAINING
DRAINING
Tools
Time
5 min
1
Turn the drain valve anti-clockwise to open and drain the water
from the boiler.
3.4 AUTOMATIC AIR VENT
AUTOMATIC AIR VENT
Tools Time
5 min
1
Drain boiler (see 3.3). Remove the clip and lift the AAV from the
assembly
3.5 PRIMARY WATER PRESSURE SENSOR
PRIMARY WATER PRESSURE SENSOR
Tools Time
5 min
1
Drain boiler (see 3.3). Remove the fixing clip, unplug the
electrical connector and lift the sensor from the assembly
41
MAINTENANCE GUIDE
3.6 PUMP
PUMP
Tools
Time
10 min
1
Drain boiler (see 3.3). Remove
the clip and the two screws
Disconnect the pipe and then
move the pump to the right
disengage
Remove the pump
2
Remove the sensor (see 3.5) Remove the AAV (see 3.4)
3.7 CH FILTER
CH FILTER
Tools
Time
5 min
1
Drain boiler (see 3.3)
Remove the clip
Remove the filter
42
MAINTENANCE GUIDE
3.8 DHW FLOW SWITCH ASSEMBLY
DHW FLOW SWITCH ASSEMBLY
Tools Time
5 min
1
Drain boiler (see 3.3). Remove the clip and pull the
flow switch assembly towards you
Twist the flow switch assembly to disengage
3.9 LEFT HAND HYDRAULIC BLOCK ASSEMBLY
1
2
3
4
5
1. Left hand hydraulic block 4. Central heating ow
2. By-pass assembly 5. Domestic hot water outlet
3. Safety valve
43
MAINTENANCE GUIDE
SECONDARY HEAT EXCHANGER
Tools
Time
10 min
1
Drain primary and domestic hot water circuits. Remove the two
screws and remove the heat exchanger
3.12 CONDENSE TRAP
CONDENSE TRAP
Tools Time
5 min
1
Unscrew the condense trap from the condense
body
3.10 SECONDARY HEAT EXCHANGER
3.11 CONDENSATE TRAP
44
MAINTENANCE GUIDE
3.13 SAFETY VALVE
SAFETY VALVE
Tools
Time
3.14 BY-PASS ASSEMBLY
5 min
1
Drain boiler (see 3.3). Disconnect the
discharge pipe
Remove the first clip on the left and
pull the safety valve towards you
BY-PASS ASSEMBLY
Tools
Time
5 min
1
Drain boiler (see 3.3). Remove the
second clip and pull the assembly
toward you
Push on the by-pass to disengage it
3.12 SAFETY VALVE
3.13 BY-PASS ASSEMBLY
45
MAINTENANCE GUIDE
3.16 MANUAL AIR VENT
MANUAL AIR VENT
Tools
5 min
Time
1
Drain boiler (see 3.3)
Remove the clip and lift the manual air vent from the exchanger
3.15 MANUAL AIR VENT
3.14 TEMPERATURE SENSOR
Tools
Time
5 min
1
NTC1
NTC2
NTC1 : Black wires
NTC2 : Grey wires
Unplug the electrical connectors Remove the clip and the tempe-
rature sensor
TEMPERATURE (°C) RESISTANCE (kOmh)
0 27
10 17
20 12
25
10
30 8
40 5
50 4
60 3
70 2
80 1,5
46
MAINTENANCE GUIDE
3.17 MAIN HEAT EXCHANGER
MAIN HEAT EXCHANGER
Tools
Time
20 min
1
Drain boiler (see 3.3). Remove
the four clips and disconnect the
two pipes between the
exchanger and pump and
between the exchanger and left
hand hydraulic block
Isolate the gas supply. Remove
the four screws and disconnect
the gas pipe from the gas valve
Remove the four screws to free
the heat exchanger
2
Pull the heat exchanger towards
you
Remove the clip and lift the
manual air vent
Twist the thermal fuse to
remove
3.16 MAIN HEAT EXCHANGEUR
47
MAINTENANCE GUIDE
4 BURNER UNIT
LEGEND
1. Burner 6. Gas valve
2. Fan 7. Mixing tube
3. Silencer 8. Detection electrode
4. Gas inlet 9. Ignition electrode
5. Air inlet 10. Spark generator
48
MAINTENANCE GUIDE
4.1 SPARK GENERATOR
4.2 ELECTRODES
SPARK GENERATOR
Tools
5 min
Time
1
Unplug the ignition electrode from
the spark generator
Remove the screw and the
spark generator
ELECTRODES
Tools
5 min
Time
1
Unplug the electrodes
Remove the screws and pull the
electrodes towards you.
49
MAINTENANCE GUIDE
4.3 BURNER
BURNER
Tools
15 min
Time
1
Remove the silencer
Isolate the gas supply. Remove the
four screws and disconnect the
gas pipe from the gas valve
Pull the assembly towards
you
2
Pull the burner toward you
Remove the three screws to free
the burner door
Replace any gaskets that are damaged or showing signs of
deterioration
1. Stainless Steel Burner
1
3
2
2. Ignition electrode
Power Length Venturi
24 KW 104.6 mm Ø 42 mm
30 KW 135.8 mm /
38 KW 167 mm
3. Detection electrode
/
50
MAINTENANCE GUIDE
4.4 FAN
FAN
Tools
Time
15 min
1
Remove the three screws to free the
fan.
Remove the combustion
assembly (see 4.3)
Twist the gas valve anti-clockwise to
disengage it from the fan
1. Venturi
2. Gasket
3. Fan
Fan & mixer venturi according to the model
Power Fan Venturi diameter
24 KW
EBM RG 128 45 W Ø 17 mm
EBM RG 128 45 W Ø 21 mm
30 KW
EBM RG 128 45 W Ø 25 mm
38 KW
51
MAINTENANCE GUIDE
4.5 GAS VALVE
GAS VALVE
Tools
Time
15 min
1
Replacement Gas Valves are
not factory set and will need to
be set up (see page 34)
Remove the combustion
assembly (see 4.3)
Twist the gas valve anti-clockwise to
disconnect it from the fan
Bayonet
connection
1. Venturi 4. Inlet test nipple
2. Gas valve 5. Offset adjustment
3. Solenoids 6. Throttle adjustment
52
MAINTENANCE GUIDE
Condensate trap
Maintenance Interval: Annually
or after cleaning primary heat exchanger
How : Visual inspection / Clean as necessary /
Add water before replacing
Pump
Maintenance Interval: At the first ignition and annually
How: Check that the AAV is open /
Visual inspection / Clean as necessary
Plate heat exchanger
Maintenance Interval: As necessary
How: To measure specification of DHW performance.
By-pass & Safety valve
Maintenance Interval: Annually
How: Visual inspection / Clean as necessary
Central heating filter
Maintenance Interval: Annually
How: Visual inspection / Clean as necessary
Flow switch operation
Maintenance Interval: Annually
How: Visual inspection / Clean as necessary
/ Check flow rate
Expansion vessel
Maintenance Interval: Annually
How: Check air pressure is at 1 bar (System drained)
Ignition & detection electrodes
Maintenance Interval: Annually
How: Visual inspection / Clean as necessary / Distance from the
burner / Ionisation current more than 1 µA
Burner
Maintenance Interval: Annually
How: Visual inspection / Clean as necessary
Fan
Maintenance Interval: Annually
How : Visual inspection / Clean as necessary
Primary Heat exchanger
Maintenance Interval: Annually
How : Visual inspection / Clean as necessary
5 ANNUAL MAINTENANCE
GAS BOILER SYSTEM COMMISSIONING CHECKLIST
CONTROLS
Tick the appropriate boxes
Time and Temperature Control to Heating Room Thermostat and Programmable
Load/Weather Optimum Start
Programmer/Timer
Room Thermostat Compensation Control
Time and Temperature Control to Hot Water Cylinder Thermostat and Programmer/Timer
Combination Boiler
Heating Zone Valves Fitted Not Required
Hot Water Zone Valves Fitted Not Required
Thermostatic Radiator Valves Fitted Not Required
Automatic Bypass to System Fitted Not Required
Boiler Interlock Provided
ALL SYSTEMS
The system has been fl ushed and cleaned in accordance with BS7593 and boiler manufacturer’s instructions Yes
What system cleaner was used?
What inhibitor was used? Quantity
litres
CENTRAL HEATING MODE
Measure and Record:
Gas Rate
m
3
/hr OR
ft
3
/hr
Burner Operating Pressure (if applicable)
mbar OR Gas Inlet Pressure mbar
Central Heating Flow Temperature
°C
Central Heating Return Temperature
°C
COMBINATION BOILERS ONLY
Is the installation in a hard water area (above 200ppm)? Yes No
If yes, has a water scale reducer been fi tted? Yes No
What type of scale reducer has been fi tted?
DOMESTIC HOT WATER MODE Measure and Record:
Gas Rate
m
3
/hr OR
ft
3
/hr
Burner Operating Pressure (at maximum rate) mbar OR Gas Inlet Pressure (at maximum rate) mbar
Cold Water Inlet Temperature
°C
Hot water has been checked at all outlets Yes
Temperature
°C
Water Flow Rate
l/min
CONDENSING BOILERS ONLY
The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798 Yes
ALL INSTALLATIONS
If required by the manufacturer, record the following CO
2
% OR CO ppm OR CO/CO
2
Ratio
The heating and hot water system complies with the appropriate Building Regulations Yes
The boiler and associated products have been installed and commissioned in accordance with the manufacturer’s instructions Yes
The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes
The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes
*
All installations in England and Wales must be notifi ed to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme.
A Building Regulations Compliance Certifi cate will then be issued to the customer.
©Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk
Commissioning Engineer’s Signature
Customer’s Signature
(To confi rm satisfactory demonstration and receipt of manufacturer’s literature)
This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating
compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.
Customer Name Telephone Number
Address
Boiler Make and Model
Boiler Serial Number
Commissioned by (print name) CORGI ID Number
Company Name Telephone Number
Company Address
Commissioning Date
To be completed by the customer on receipt of a Building Regulations Compliance Certifi cate
*
:
Building Regulations Notifi cation Number (if applicable)
!
SERVICE RECORD
It is recommended that your heating system is serviced regularly and that the appropriate Service Record is completed.
Service Provider
Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s
instructions.
Always use the manufacturer’s specifi ed spare part when replacing controls.
SERVICE 1 Date
Energy Effi ciency Checklist completed? Yes
No
Engineer Name
Company Name
Telephone Number
CORGI ID Number
Comments
Signature
SERVICE 3 Date
Energy Effi ciency Checklist completed? Yes
No
Engineer Name
Company Name
Telephone Number
CORGI ID Number
Comments
Signature
SERVICE 5 Date
Energy Effi ciency Checklist completed? Yes
No
Engineer Name
Company Name
Telephone Number
CORGI ID Number
Comments
Signature
SERVICE 7 Date
Energy Effi ciency Checklist completed? Yes
No
Engineer Name
Company Name
Telephone Number
CORGI ID Number
Comments
Signature
SERVICE 9 Date
Energy Effi ciency Checklist completed? Yes
No
Engineer Name
Company Name
Telephone Number
CORGI ID Number
Comments
Signature
SERVICE 2 Date
Energy Effi ciency Checklist completed? Yes
No
Engineer Name
Company Name
Telephone Number
CORGI ID Number
Comments
Signature
SERVICE 4 Date
Energy Effi ciency Checklist completed? Yes
No
Engineer Name
Company Name
Telephone Number
CORGI ID Number
Comments
Signature
SERVICE 6 Date
Energy Effi ciency Checklist completed? Yes
No
Engineer Name
Company Name
Telephone Number
CORGI ID Number
Comments
Signature
SERVICE 8 Date
Energy Effi ciency Checklist completed? Yes
No
Engineer Name
Company Name
Telephone Number
CORGI ID Number
Comments
Signature
SERVICE 10 Date
Energy Effi ciency Checklist completed? Yes
No
Engineer Name
Company Name
Telephone Number
CORGI ID Number
Comments
Signature
!
55
SHORT LIST
Ind 01 - 07/03/2008
Key N
Description
Manf. Pt.N
Type
Manf. date
from to
E-COMBI
24 30 38
0100 BURNER ASSEMBLY
0110 IGNITION ELECTRODE 61317432
...
0111 IONIZATION ELECTRODE 61317433
...
0112 GASKET D:85-66.5-2.5 61314753
...
0134 ELECTRODE GASKET 60000286
...
0135 COMBUSTION CHAMBER LINING KIT 60000297
...
0136 DOOR GASKET 60000623
...
0400 GAS SECTION
0401 GAS VALVE 60000537
...
0407 FAN ASSY 60000622
...
0500 HYDRAULIC BLOCK
0502 MOTOR - THREE-WAY VALVE 61302483
...
0506 3-WAY SPRING KIT (D.H.W.) 65104314
...
0517 LOW PRESSURE SWITCH 65105090
...
0530 AUTO AIR VENT WITH O-RING 65104703
...
0537 PRESSURE RELIEF VALVE 61312668
...
0538 PUMP 5M 2V 65104319
...
0543 SENSOR (REED) 65104323
...
0589 SECONDARY EXCHANGER 65104333
...
0590 LIP SEAL 61002249
...
0600 ELECTRICAL BOX
0607 IGNITER 61002105-20
...
0615 PRINTED CIRCUIT BOARD 60001129
...
0616 PRINTED CIRCUIT BOARD (DISPLAY) 60001130
...
0625 PRESSURE GAUGE 65104234
...
136
135
112
134
111
110
537
407
401
517
538
530
589
590
502
506
615
607
625
616
SHORT LIST
543
E-COMBI
420010127600 - 02/2008
Commercial subsidiaries: MTS (GB) Limited Professional Team Limited
MTS Building Suites 9 & 10, Plaza 256
Hughenden Avenue Blanchardstown Corporate Park 2
High Wycombe Ballycoolin
Bucks HP13 5FT Dublin 15
Telephone: (01494) 755600 Telephone: (01) 810 3723
Fax: (01494) 459775 Fax: (01) 810 3727
Internet: www.mtsgroup.com/uk Internet: www.mtsgroup.com/ie
E-mail: info@uk.mtsgroup.com E-mail: info@ie.mtsgroup.com
Technical Advice: 0870 241 8180 Technical Advice: (01) 437 0121
Customer Service: 0870 600 9888 Customer Service: (01) 437 0121
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